Towards a Simpler Selection Process for Maintenance Strategies

Kenneth Robson, John MacIntyre, Robert Trimble

Abstract

Recent research at four large manufacturing sites in the North East of England showed that maintenanceorganisations were failing because they were locked in a cycle of quick fix and mend despite deploying extensiveplanned maintenance policies. Consequently they were unable to plan and formulate strategies because they didnot have the time. Simple and quick tools were needed to select the best maintenance approach for the machinesand the plant. Two possible selection tools were developed. Firstly a truth table was produced based on the keycharacteristics of each maintenance approach and these mapped against simplified failure mode combinations.This offered a quick and easy selection method for machines, based on failure mode patterns. Secondly, themacro level was addressed using a conceptual model employing a 2x2 matrix. This consisted of two axes, thelevel of machine failures and the level of improvement activity. The resulting framework was used to predicthow maintenance organisations would progress from a state of reactive maintenance towards world class. Theninformed by the truth table it was possible to select an appropriate maintenance approach which was mostsuitable for each stage. It is suggested that these two methods offer simple and quick approaches to guide vitalmaintenance decision making at plants in difficulty. This of course does not preclude the need to developmaintenance strategies but rather facilitates this process by freeing up time and resources.

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